rp112_s01_titel en.indd

Zukunftsmarkt erneuerbare Energien

Grünes Gold

Focus on China

Sustainable Growth

newsprocess

Volume 16, Number 2, 2011

The Magazine for the Process Industry

C o n t e n t s

Siemens provides the integrated automation system for Sinopec’s flagship refinery and petrochemical complex in China

Page 4

p r o c e s s n e w s | 2 - 2 0 1 1

2 process news | 2-2011

p Focus

China 4 Petrochemical Megaproject

Sinopec Qingdao Refining and Chemical Corporation Ltd.

8 Pulling It All TogetherLongda Differential Chemical Fiber Co. Ltd.

11 Partners for GrowthSciample Technology Co. Ltd.

12 Water GuardianXi’an City Authorities

13 Compensating for ViscosityFlow metering

14 East Meets WestWacker Chemicals Co. Ltd.

18 Chain of ExcellenceShanxi Luneng Jinbei Aluminum Limited Company (LNJB)

20 Growth through ExpertiseSIAS

22 Trusted PartnerNorth China Pharmaceutical Group Corp.

24 In Brief Asia

p Technology

Process Analytics 25 Strictly Controlled and

Eco-FriendlyVent Gas Unit

p Industry

Plastics 26 Clever Compound

Buss AG, Switzerland

Food and Beverage 28 Consistently Unique

Palm Breweries, Belgium

Oil and Gas 30 Virtual Drilling

Aker MH, Norway

32 In Brief

33 Dialogue

The high-performance Buss kneaders utilize Simatic technology for maximum flexibility and safety

6

The new Longda cellulose fiber plant benefits from maximum process safety, consistent product quality, and reduced operational costs

Page 8

Go

ng

kon

g

Go

ng

kon

g

Buss

AG

E d i t o r i a l

process news | 2-2011 3

Dear Readers:

The cover of this issue of process news, which focuses on the Chinese

process industry, shows bamboo. You may wonder why we chose this photo.

Well, fi rst of all, like bamboo, the Chinese process industry market is

growing very fast. Second, both our customers and we at Siemens are

currently making great efforts to make this growth sustainable. The bamboo

stands for the need to “go green” – to protect valuable resources and to

ensure safe and effi cient plant operation. Moreover, sustainability is also

essential to ensuring long-term business success.

Today, our customers pay greater attention to the management of the entire

production lifecycle. They rely on modern automatic control technology in

upgrading plant productivity by reducing equipment shutdown time, in

increasing operational safety, in ensuring long-term investment protection,

and in shortening product lead times.

Our unique set of process control and automation systems based on Totally

Integrated Automation helps our customers reduce their costs for

engineering design, plant operation, and upgrading. Our Simatic PCS 7

process control system offers a powerful tool for performance optimization

and has been widely used in the petrochemical, chemical, metallurgical,

pharmaceutical, cement, and power industries. Here in China, it has been

successfully deployed in several major projects, including the 10-milllion-ton

Qingdao oil refi ning project of Sinopec, the aluminum oxide project of

Shanxi Jinbei Aluminum Co. Ltd., and the pharmaceutical project of Novartis.

You can read more about these applications in this issue of process news.

As global players in the process industry move to China, the Chinese process

industry market will become a global hot spot, and I am confi dent that we

can support our customers in making their operations more effi cient and

more competitive – and in turning this growth into sustainable success.

Yours,

Wang Hai Bin

Senior Vice PresidentSiemens Ltd., China

General ManagerIndustry Automation DivisionIndustry SectorSiemens Ltd., China

all p

ho

tos:

Go

ng

kon

g

Foto

lia / T

ho

mas

Nit

z

F o c u s C h i n a


Siemens provides the integrated automation system for a fl agship refi nery and

petrochemical complex in China with a capacity of 10 million tons per year.

p Sinopec Qingdao Refi ning and Chemical Corporation Ltd., China

Petrochemical Megaproject

The Qingdao refi nery is a milestone for both the plant owner, Sinopec, and the entire Chinese petrochemical industry

the booming Chinese economy was generating strong growth in demand for refinery and petro-chemical products. The growing awareness of safety and environmental protection issues in China also meant that any new plant would need to comply with new, tightening regulations. Sinopec needed to build a refi nery that would compete with the best in the world, and build it quickly.

When Sinopec (China Petroleum & Chemi-cal Corporation), the largest producer of refi ned oil products in China, initiated a

project to build a new integrated oil refi nery capable of processing 10 million tons of crude oil per year in Qingdao in 2005, the company was facing a number of challenges, both technical and commercial. The cost of oil on the world markets was increasing, and


» We consider the main automation

vendor strategy to be the best

solution for a modern large-scale

petrochemical project. Plus, we

needed a world-class automation

systems integrator to act as

our partner. «Huang Buyu, Consultant of Sinopec Instrument Specialist Committee, Deputy Chief Engineer, and Specialist Committee Member, Sinopec Engineering Incorporation

Sinopec is one of the largest integrated energy and chemical companies in China. It is China’s second largest producer of oil and gas and the third largest oil refi ner in the world. The new refi nery, in addi-tion to being of major importance to Sinopec, would be of strategic importance to China, as it would have the highest throughput of any single refi nery plant in the country. To optimize the use of resources and energy and to minimize emis-sions, Sinopec planned an integrated refi nery and petrochemical complex. Central to the operation would be the use of the latest information and automation technologies to manage the production processes and enable ongoing technology innova-tion. In this project, Sinopec followed a strategic main automation vendor approach, says Huang Buyu, a consultant of Sinopec Instrument Specialist Committee, deputy chief engineer, and Specialist Committee member at Sinopec: “We consider the main automation vendor strategy to be the best solution for a modern large-scale petrochemical project. Plus, we needed a world-class automation systems integrator to act as our partner.”

Integrated automation systemSinopec drew up specifi cations for the integrated automation system that included everything from instrumentation, HMI, and safety to data archiving, inventory control, and services for maintenance. In 2006 Siemens won the invitation to tender for the integrated automation system contract with a pro-posal based on the Simatic PCS 7 distributed control system. This was potentially a big step for Simatic PCS 7. Although the process control system was in wide use in many industries, Simatic PCS 7 had not been used in such a large oil and petrochemical application before.

The technical challenge was not the only one. The overall engineering investment was in the range of

US $2 billion, and production was scheduled to start by 2008. The refi nery project included 15 separate plants, utilities, and assemblies. The automation system provider would be required to make full use of Chinese-localized hardware and software manu-facturers and support services and coordinate the work of fi ve major Chinese and international con-tractors.

T h e Q i n g d a o r e f i n e r y p r o j e c t a n d p l a n t s

3 Total investment: US $2 billion

3 Capacity: 10 million tons crude oil processing per year

3 Atmospheric and vacuum distillation

3 Fluid catalytic cracking

3 Delayed coking

3 Hydrotreating

3 Catalytic reforming

3 Diesel hydrotreating

3 Kerosene hydrotreating

3 Gas fractionation

3 Sulfur recovery

3 Desulfurization sweetening

3 Solvent regeneration

3 Sour water stripping

3 Hydrogen manufacturing

3 Polypropylene, etc.

F o c u s C h i n a


» We are giving priority

to Siemens in our new

projects this year. Even

when other companies are

recommended, we still

choose Siemens fi rst. «Chen Xin, Instrument Director, Qingdao Refi ning & Chemical Co. Ltd.

To optimally support Sinopec, Siemens set up a project team that combined and integrated all the competencies of the Siemens expert network: petrochemical industry experts from the Siemens headquarters in Germany, local industry specialists from Siemens in China, and systems integrators and engineering experts from Siemens Industrial Auto-mation Ltd., Shanghai (SIAS). The Siemens bid was successful, and on February 7, 2007, a contract for the project was signed. The commissioning of the plant was completed and production began on schedule in June 2008. In 2009 the plant processed 9.47 million tons of crude oil, making a valuable contribution to China’s national economy.

The heart of the new Chinese petrochemical industryQingdao is a new Economic and Technological Development Zone located on China’s Bohai Bay coastline. With the new refi nery, Qingdao – which by tradition has a strong link to industry – has emerged as the heart of the new Chinese petro-chemical industry. The Sinopec refi nery and petro-chemical complex is located on a greenfield site chosen for its good infrastructure and geographic location with water access.

In the refi nery, crude oil undergoes a series of atmo-spheric and vacuum distillation processes and cata-lytic cracking. The refi nery yields a broad spectrum of products, including gasoline, aviation kerosene, diesel, polypropylene, benzene, and other industrial chemicals. Several new advanced technology pro-

cesses are employed in the plant to optimize material and energy use and minimize emissions. A delayed coking plant processes the waste products from the distillation stages to release further eco-nomically useful materials. The waste from the delayed coking unit then goes into a circulating fl uidzed bed boiler, where it is burned with minimal emissions to create energy for use elsewhere in the plant. In this way, all the material and energy in the crude oil are utilized. Nothing is wasted.

Comprehensive services for a comprehensive solutionSiemens supplied all the hardware and software for the automation solution or concept of the mega-plant, complete with associated services over the lifecycle. Moreover, Siemens and SIAS supported Sinopec in procurement, hardware and software factory acceptance testing, training, system commis-sioning and start-up, and ongoing maintenance.

The distributed control system at Qingdao is vast and complex. The central control room has fi ve main operational areas with 93 operation stations and also features a large closed-circuit television (CCTV) system. There are 46 pairs of dual-redundancy fault-tolerant Simatic PCS 7 AS 400 automation systems linked via Profi bus, monitoring 20,000 hard I/O and 15,000 soft I/O signals. There are 90 interface links to third-party systems via dual fi rewalls. The system also interfaces with operational systems such as the compressor control, safety instrumented systems (SIS), and gas detection systems. The plant informa-

all p

ho

tos:

Go

ng

kon

g


infocontact

www.siemens.com/[email protected]

The central control room provides detailed information on plant and process status

S i m a t i c P C S 7 i n Q i n g d a o : k e y b e n e f i t s

3 Depth of experience of Siemens as a trusted partner

3 High-quality DCS products and engineering service

3 Shortest possible time to production and market launch

3 Optimized production safety, reliability, stability, and fl exibility

3 High return on investment

3 Lower production cost and improved quality

tion management server links with the asset man-agement system and long-term archive server.

Sinopec is proud of its new plant in Qingdao, and states on its Web site that the plant helps move the company toward its goal to “Build the world-class refi ning and chemical enterprise.” In a recent inter-view, Chen Xin, instrument director, praised the quality and stability of the Siemens controllers and industrial hardware and the effort Siemens made in the customization of the Simatic PCS 7 software. He said the team was also pleased with Siemens’ prompt response in problem solving, noting that Siemens engineers, both from Germany and based in China, had made special visits to Qingdao: “The Siemens engineers investigated the problems on-site and took the problems back for further study and improvement.” Chen would have no hesitation in using Siemens for upcoming projects. “We are giving priority to Siemens in our new projects this year,” he said. “Even when other companies are recom-mended, we still choose Siemens fi rst.” p


Mention “clothing made from wood pulp” and one might think of the faddish paper dresses made in the late 1960s and early

’70s. But clothing made from cellulose fi ber from wood pulp has been with us for years, under the names rayon and acetate. Viscose chemical fi ber is another type of cellulose fabric. Like cotton, viscose textiles are softer and more absorbent than polyes-ter, but unlike natural cotton they retain dye vividly. In addition to clothing, viscose fi bers are used for a multitude of purposes, ranging from surgical scrubs and wound dressings to nonwoven products such as diapers and towels, as well as in technical applica-tions such as conveyor belts and tire cords. Viscose fi bers are also a major feedstock in the production of carbon fi ber.

With a reliable, high-performance process control solution

based on Simatic PCS 7, a new cellulose fi ber plant benefi ts

from maximum process safety, consistent product quality,

and reduced operational costs.

With this vast range of markets, the demand for vis-cose fi ber is steadily growing. However, fi ber produc-ers face strong competition. Additionally, environ-mental concerns about large chemical processing plants affect the textiles industry, so manufacturers must implement strategies to produce top-quality fi bers at competitive costs with maximal safety and minimal environmental impact. Longda Differential Chemical Fiber considered these challenges when building a new viscose fi ber plant in Jiujiang, Jiangxi province.

A complex process pulled neatly togetherThe Longda fi ber plant is one of the largest cellulose fi ber production plants in China. Built in 2008 on the banks of the Yangtze River, which enables the ship-

p Longda Differential Chemical Fiber Co. Ltd., China

Pulling It All Together

F o c u s C h i n a

Foto

lia / t

ou

rne

e


ping and receiving of bulk goods, the new factory can produce 110,000 tons of viscose chemical fi ber per year. Two of the three lines are already in opera-tion, and the third line is currently in commissioning.

The complex production process in this plant is con-trolled by a distributed control system (DCS) based on Simatic PCS 7. Longda was impressed by the system’s excellent track record in the cellulose fi ber industry and the performance of Siemens automation prod-ucts. “We have used Siemens products for years, and they are very reliable. Siemens has cutting-edge auto-mation technologies and products,” said Lan Ching-ming, vice general manager of Longda.

“The etiolation production process includes 13 steps, all of which are automatically controlled by the Simatic PCS 7 system,” he explained. “At the begin-ning of the process, wood pulp is alkalized, then turned into a honey mash by adding carbon disulfi de. This step needs to be exactly monitored and con-trolled, as carbon disulfi de is a highly explosive sub-stance at a certain temperature level and it impacts the quality of the spun fi ber at a later stage.” The chemical substances are classifi ed as hazardous to human health and the environment, so precise con-trol is essential for maximum process safety. Addi-tionally, the process requires effi cient motors and drives to guarantee smooth fi ltering, heating, spin-ning, airing/cooling, and purifi cation.

“Viscose is a natural, very expensive product, so one has to be careful during production,” adds Lan. “The viscose must always be at an optimal level of matu-rity – and it matures quickly – so that each batch has the same quality. The automation systems and the electrical equipment must be absolutely reliable to

One of the core batch process steps in fi ber production: the wet spinning machine is precisely controlled by Simatic PCS 7 and Siemens motor control centers J i a n g x i T a i D e E n g i n e e r i n g C o . L t d .

A wholly owned subsidiary of the Jiangxi Textile Institute, Tai De Engineering was founded in 2006 and now has more than 60 percent of the automation market share in the Chinese viscose production industry. Most of Tai De’s customers have 5,000 to 13,000 I/O points to manage, and produce an output of 60,000 to 200,000 tons per year.

Thanks to Tai De’s extensive experience and reputation in the chemical fi ber industry, the company has developed its own chemical fi ber content control software, which has been certifi ed as its intellectual property by the Chinese National Copyright Administration.

“Our software is relevant to the viscose production process,” says Wan Yi Ming, general manager of Tai De. “We know the technology very well, including demands and process control. Tai De is a high-tech enterprise and is certifi ed according to ISO9001. We have incorporated quality standards in our processes, and each program is independent.

“The reliability of the system is very crucial for us. Any disturbance will generate waste, so we have to prevent a malfunction from occurring. Therefore, all our controllers, power supplies, and Industrial Ethernet cards, and even all the networks, are redundant to ensure absolute system reliability.

“Tai De has a long history of working with Siemens products. Our relationship with Siemens is growing stronger and stronger. If we have diffi culties during operation, Siemens offers a toll-free hotline, ongoing training, and on-site support by dispatching technicians. That service is important to satisfy the customer, as we provide a turnkey solution.

“Growth with Siemens is also a key factor for us. Since our customers are all around China, Siemens can provide the optimum regional sales and technical support that we cannot provide throughout China.”

» Siemens can

provide regional

sales and

technical

support. «Wan Yi Ming, General Manager,Tai De

all p

ho

tos:

Go

ng

kon

g

all p

ho

tos:

Go

ng

kon

g


infocontact


avoid high service costs and considerable production losses. With the established and proven products from Siemens, we can minimize cost and risk by standardization. Simatic PCS 7, the motor control center (MCC), and positioners, to name a few, ensure a very stable process.”

Excellence in automation and monitoringEach step in the production process is automatically controlled, and when one step ends, the next step begins automatically. The high level of automation results in immediate savings: Without automation, a plant of this size would require a staff of 3,000. Thanks to the Simatic PCS 7 solution, the plant is run by a crew of 600.

“Previously, the monitoring was performed in the production line, and monitoring staff went to the

site to record data once an hour,” said Lan. With the Simatic PCS 7 control system, more than 8,000 con-trol points are recorded instantaneously and sent to the control room. “If the temperature is out of scope, it will be refl ected in the control center,” he stated. “In this way, we can identify problems and deal with them immediately.”

Demand for Longda’s products is large – each day Longda ships out 300 tons of goods from its wharf on the Yangtze River. Reliable production is a must, and the Simatic PCS 7 DCS has made that a reality. p

F o c u s C h i n a

» We have used

Siemens products

for years, and they

are very reliable.

Siemens has cutting-

edge technologies. «Lan Chingming, Vice General Manager Longda

Ready for shipping: the fi nished viscose fi ber is packed in bales. Each day Longda ships out 300 tons of viscose fi ber

More than 8,000 control points are recorded instantaneously in the Simatic PCS 7 control system for monitoring process safety and guaranteeing production quality. Operators can identify and resolve problems immediately


F o c u s C h i n a

Foto

lia / S

un

nyd

ays

Helping protect China’s energy resources and environment has always been a key

value for Sciample. The Siemens Automation Solution Partner provides high-tech

solutions that will help economic growth in China become sustainable.

p Sciample Technology Co. Ltd., China

Partners for Growth

Along with the rapid development taking place in China’s economic boom, shortages in energy and natural resource supplies are

increasingly drawing attention. Sciample Technology Co. Ltd. in Beijing, China, has always regarded sav-ing energy, reducing emissions, and optimizing resource consumption as strategic aspects of the company’s development programs. Using innovative high-tech solutions, Sciample wants to play a part in transforming and improving traditional industries in China. Consequently, the company has launched a series of energy-saving and consumption-optimizing technologies and products that offer a high rate of return on investment.

Shared values foster partnership

Founded in 2001, Sciample is a subsidiary of the Chi-nese Academy of Sciences’ Institute of Automation. Recently, Sciample was certifi ed as a Siemens Auto-mation Solution Partner. This certifi cation marks an important milestone in the collaboration between Sciample and Siemens. The two companies share key values in their development policies – a commit-ment to innovation and technology complemented by a strong belief that sustainable success is based on using resources responsibly. These shared values have contributed to successful collaboration on mul-tiple automation and process control projects.

Investment in the futureAs part of the Chinese Academy of Sciences’ Institute of Automation initiative “Sustainable Development Together,” Sciample has also created a training site for doctoral and master’s students. Together with Siemens, Sciample recently built the Joint Advanced Automation Technology Laboratory, which has been certifi ed as a skill training center and engineering skills testing center with an Automation System Engineer Accreditation (ASEA) by the Chinese Asso-ciation of Automation. This educational facility, which represents an important investment in the future of China’s process industry, will train the engi-neers who will set China on a path toward truly sus-tainable growth. p

S c i a m p l e T e c h n o l o g y C o . L t d .

3 Advanced system integrator 3 Simatic PCS 7 solution partner 3 Energy-saving system integrator

Areas of specialization include integrated energy optimization, intelligent scheduling, advanced control technology, automation integration, infrared products, and RFID products.

The company has more than 160 employees, including 50 experienced PLC/DCS engineers, 15 of whom have a Siemens Automation Expert Certifi cate

Sciample has realized over 400 projects, mostly in the coking, metallurgy, and petrochemical industries.

www.sciample.com

info

contact

www.siemens.com/automation/[email protected]


Ecological benefi ts

The project was executed smoothly, and both the plant operator and the systems engineering com-pany are very satisfi ed with the plant performance. The Simatic-based automation technology ensures reliable treatment performance and smooth opera-tion of all systems. With Xi’an 4 in operation, city authorities have raised the share of treated waste-water to 80 percent. In the meantime, the fi fth Xi’an plant has been commissioned (at the end of 2010), and a sixth facility is currently in the design phase. The wastewater treatment plants, Xi’an’s new guard-ian army, have already delivered visible results: the water quality of the River Wei in the north of Xi’an has improved signifi cantly. p

In Xi’an, city authorities have taken effective

measures to protect natural resources, and

the wastewater treatment system has already

improved river water quality signifi cantly.

One key facility is the recently commissioned

Xi’an 4 treatment plant, which was

automated with Simatic technology.

Home to the famous Terracotta Army guard-ing the tomb of Qin Shi Huang, the First Emperor of China, Xi’an looks back on a long

history as the cultural and economic center of the Shanxi province in the central northwest region of China. During the past few decades, the city has also emerged as one of China’s current economic hubs. Xi’an and its surrounding urban area are home to more than nine million people. However, this eco-nomic and population growth also necessitated a huge investment in infrastructure. One concern especially was treating the city’s wastewater. Conse-quently, the city of Xi’an has built several waste-water treatment plants to guard one of the most precious resources of the present: clean water.

A key plantThe Xi’an 4 wastewater treatment plant is one of the key facilities in the city’s wastewater management program. The greenfi eld plant was constructed from 2006 to 2009 and is designed to treat 500,000 m3 of wastewater per day. The automation technology for the plant was designed and engineered by Xi’an Aerospace Automation Co. Ltd., a systems engineer and automation technology specialist from Xi’an. The system in the Xi’an 4 plant uses a wide range of Siemens products, from the Simatic WinCC Super-visory Control and Data Acquisition (SCADA) system and HMI panels to Simatic S7 controllers, Profi net connections, and Sitrans process instruments.

p Xi’an City Authorities, China

Water Guardian

infocontact


Foto

lia / s

imsc

hm

idt

F o c u s C h i n a

X i ’ a n 4 a u t o m a t i o n a r c h i t e c t u r e

3 Simatic WinCC visualization system

3 Operator stations and controllers networked via Industrial Ethernet with Scalance switches

3 Simatic S7-400 controllers

3 Simatic MP 277 panels for local operation and monitoring

3 Distributed Simatic ET 200 systems networked via Profi bus DP

3 Sitrans fl ow, temperature, and pressure instruments

’ a

im

Opeia

im

imnd

Distnetw

itranst

ae

acotta Army guard-Huang, the First looks back on a longomic center of the orthwest region of

ades, the city has also ent economic hubs.

area are home to

X i

3 S

3 Ov

3 S

3 Sa

3 Dn

3 Sin

Foto

lia / C

hri

stin

a Po

lley

Foto

lia / S

tefa

n K

örb

er

Siem

ens

AG

Siem

ens

AG


F o c u s C h i n a

The Sitrans FUH1010 accounts for varying viscosities

caused by temperature changes in undulating terrain.

A pipeline operator needing a leak detection system for a new pipeline stretching 2,000 km across China had a challenging

task. The fl ow measurement part of the system had to accommodate constantly changing conditions caused by the pipeline’s route through elevations ranging from 35 to 1,900 m and temperatures fl uc-tuating from –20 °C to 40 °C. A device able to com-pensate for the varying viscosities these environ-ments impose on the oil products to be carried by the pipeline was critical.

Eliminating measurement errorThe company chose the Sitrans FUH1010 clamp-on ultrasonic fl owmeter. Its ability to compensate for viscosity, a feature unique to it, was the clincher. Without temperature and viscosity compensation, the projected fl ow measurement error would be about 3 to 4 percent, so this aspect was vital. With no insert sensors, it is considered the best choice for leak detection systems. Using the Reynolds number to determine a liquid’s fl ow profi le, it can measure different products fl owing through the pipeline with consistent accuracy.

The Sitrans FUH1010 comes in various confi gura-tions; two were ideal for the pipeline operator. The precision volume fl owmeter provides dynamically

p Flow metering

Compensating for Viscosity

viscosity-compensated straight volumetric fl ow. The standard volume meter provides fl ow with tempera-ture, viscosity, and density compensation and all the features of the precision volume meter. All meters include excellent repeatability and can measure at zero fl ow, a good feature for leak detection, as the products are not always in motion.

Accurate fl ow rateThe pipeline operator chose a precision volume con-fi guration combined with a third-party fl ow com-puter. This provides an accurate volumetric fl ow rate and accounts for viscosity changes caused by vary-ing product types and/or fl uctuating temperatures. The meter dynamically calculates viscosity to deter-minate the Reynolds number, then applies the proper compensation to the fl ow rate. All Sitrans FUH1010 fl owmeters have this feature. The Sitrans FUH1010 standard volume version calculates the standard volume on its own, but the pipeline opera-tor did not require this added benefi t since the third-party fl ow computer was able to perform the calcu-lation. p

The Sitrans clamp-on ultrasonic sensors are mounted on the pipeline at one of the 15 pump stations (left)

The display is wired to the sensors mounted on the pipeline, which at this section is buried underground (right)

infocontact

www.siemens.com/fl [email protected]

Wac

ker

Ch

emic

als

(ZJG

) C

o.,

Ltd

.

F o c u s C h i n a


Fotolia

/ roto

Graphic


presence. In 2003 Wacker built its fi rst Chinese fac-tory for the production of organosilicon emulsion in Shanghai. Siemens, as the automation partner, equipped the new factory with Simatic S7 controllers via its solution provider in China, Siemens Industrial Automation Ltd., Shanghai (SIAS). This marked the beginning of a relationship that would extend the excellent partnership of Wacker and Siemens from Europe into China and result in a truly global knowl-edge and project network that benefi ts both compa-nies.

Over the next years, Wacker expanded to four pro-duction sites in China (Shanghai, Nanjing, Wuxi, and Zhangjiagang). As each new production line was built, Siemens and SIAS were there providing electri-cal systems, process automation solutions, and the associated services. The latest site, Zhangjiagang, is by far the largest and of the greatest strategic impor-tance, both for Wacker’s partnership with Dow Corn-ing and for the manufacture of siloxane and pyro-genic silica. The site also features fi nished silicone production plants that are owned and operated inde-pendently by each company.

Economy of scale – and scalabilitySiloxane and pyrogenic silica are key ingredients in the manufacture of fi nished silicone products. Sili-cone-based materials are used in nearly all sectors of China’s booming economy, including automotive, construction, cosmetics and personal care products, electronics, power generation and distribution, solar energy, and textiles. Pyrogenic silica is used as an active fi ller in silicone elastomers; as a viscosity-

Two Chinese stone lions with the Bavarian coat of arms in their

paws welcome visitors to Wacker Chemicals’ Zhangjiagang site.

Inside, the new silica facility benefi ts from another example of

excellent cross-national collaboration: control and power supply

systems based on German technology expertise and

implemented with Chinese engineering skills.

November 2010 marked an important date in the Chinese silica industry. Wacker Chemie AG and Dow Corning Corporation

announced the inauguration of a joint silicone manufacturing site in Zhangjiagang, China. The announcement was important because the manu-facturing site covers 1 million m2, cost US $1.8 bil-lion to build, is China’s largest facility of its kind, and is among the world’s most advanced integrated sili-cone production sites. The successful establishment of the facility is due in part to a long-term relation-ship between Wacker and Siemens as the supplier of electrical and automation systems.

Wacker fi rst moved beyond the German market to become a global chemical company in the 1950s. It became a major producer and technology leader in polymer and silicone chemistry, with a worldwide

p Wacker Chemicals Co. Ltd., China

East Meets Westi

Fotoliaa

/ ro

ap

toGraphichic

H i g h l i g h t s

3 Strength of experience built up over numerous projects over many years

3 Simatic S7 used from 2003, Simatic PCS 7 from 2005

3 Batch control library reused in all projects from 2005

3 Partnership built on stable project teams both at Wacker and SIAS

3 Fast response to problems thanks to SIAS personnel on-site


adjusting agent in coatings, printing inks, adhesives, unsaturated polyester resins, and plastisols; and as a fl ow aid – for example, in the cosmetics, pharmaceu-tical, and food-processing industries.

By investing in an extremely large plant, Wacker gained economy of scale. This enabled the company to employ state-of-the-art production processes and technology to ensure high product quality and per-formance. The plant was designed to make the most effective use of raw materials through energy-effi -cient processing and sophisticated factory automa-tion and environmental control technology. The company’s progression to the Zhangjiagang siloxane and pyrogenic silica plant was made step by step via a number of smaller plants in China, where Wacker worked together with Siemens and SIAS at every stage. This staged approach helped reduce complex-ity and also contributed to building local process and project knowledge at both Wacker and SIAS.

At the fi rst factory, in Shanghai in 2003, SIAS imple-mented an entry-level control solution with Simatic S7-300 controllers and Simatic MP270 panels. This

was one of the fi rst cooperative developments using Simatic S7 technology undertaken by Wacker and SIAS and built on experience gained in Germany. The S7-300 and MP 270 series products were chosen because they offered the fl exibility to create either a centralized or decentralized automation system cov-ering both motion control and safety technology.

In 2005 Wacker established its fi rst facility in Zhangji-agang, 140 km from Shanghai, to produce redispers-ible powder. Wacker decided to equip the plant largely with Siemens technology. The power supply and distribution use Siemens medium- and low-volt-age systems. The facility’s dryer unit with 400 I/O devices in the plant also represents the fi rst installa-tion of a Simatic PCS 7 control system at Wacker China. The system engineering was performed by SIAS using standard routines and customized mod-ules written specifi cally for chemical processing applications. The resulting batch control library was employed by Wacker in every subsequent project.

The next two large projects were the fumed silica plant and the Wacker-Dymatic silicones project. Both

Powerful medium-voltage transformers from Siemens enable a reliable power supply

F o c u s C h i n a » Due to its openness and scalability,

Simatic PCS 7 is a stable system that

runs smoothly for years. «Hu Jianhu, DCS Engineer, Wacker Chemicals, Zhangjiagang

Operators in the Zhangjiagang facility benefi t from the excellent usability provided by Simatic PCS 7

all p

ho

tos:

Wac

ker

Ch

emic

als

(ZJG

) C

o.,

Ltd

.


facilities are also equipped with a Simatic PCS 7 sys-tem engineered by SIAS. With 900 I/O devices in the Dymatic plant and a planned 7,000 I/O devices in the fumed silica plant, these two control system projects were signifi cantly larger. Next came a redispersible powder project, in which SIAS also implemented a batch control solution based on Simatic Batch. The second phase of the pyrogenic silica plant began construction in 2009, and in the same year Wacker and SIAS signed contracts for several other projects as well.

Consistency in collaborationThanks to the scalability of Simatic PCS 7, Wacker and SIAS were able to use the experience gained from earlier projects, which created synergies and helped streamline projects. Each Simatic PCS 7 proj-ect built on this pool of expertise, providing opti-mum system stability and reliability. The fl exibility and openness of the Simatic architecture has enabled SIAS to stay with essentially the same sys-tem from one factory in 2005 to a site covering 1 km2 in 2010. Siemens has provided a truly integrated system that is able to interface with all

electrical and automation systems both from Siemens and from third-party manufacturers.

This consistency in collaboration has helped Wacker transfer know-how from Germany to China, both in terms of hardware and technology and in terms of staff capabilities and service. Wacker has used Siemens almost exclusively in its chemical plants in China not because of any contractual ties but because Siemens has consistently delivered cost-effective systems meeting Wacker’s specifi cations and deadlines. When asked recently, Hu Jianhu, dis-tributed control system (DCS) engineer at Wacker’s Zhangjiagang facility, commented, “A partner has to be there when needed. With SIAS, the projects are executed completely to customer requirements.” p

infocontact


The vast facility in Zhangjiagang from a distance (top) – and up close (bottom): numerous panels enable local monitoring and operation

T h e S i e m e n s t e c h n o l o g y p a c k a g e

3 Simatic PCS 7 process control system

3 Simatic S7-300 controllers

3 Simovert drives with Simocode devices

3 Motor control centers

3 Simatic ET 200iSP devices

3 Switching systems and devices

3 Profi bus DP communication technology

3 Medium-voltage/low-voltage substation

3 20 kV medium-voltage switchgear

3 Low-voltage switchgear systems

3 Transformers

A piece of Germany in China – Burghausen Road runs through the Wacker premises in Zhangjiagang

Foto

lia / t

ou

rne

e


p Shanxi Luneng Jinbei Aluminum Limited Company (LNJB), China

Chain of Excellence

After the successful deployment of

Simatic PCS 7, an alumina processing

facility benefi ts from signifi cantly

higher effi ciency and safety.

Relying on the abundant coal and aluminum resources in northern Shanxi province, Shanxi Luneng Jinbei Aluminum Limited Company

(LNJB) operates a complete aluminum production chain providing processing capacity for 3.6 million tons of bauxite per year. For this purpose, LNJB initiated an ambitious construction project to build an alumina refi nery with a capacity of 3 million tons per year and an alumina smelter plant with a capac-ity of 1 million tons per year and a target aluminum output of 100,000 tons per year as well as other auxiliary plants such as a power plant and cement plant.

Effi ciency and reliability are key elementsThe production of alumina, in which bauxite is refi ned using the Bayer process, is very complex. The process is also highly energy intensive, so energy effi ciency is a must. The LNJB facility is one of very few plants globally that integrates the entire production process from bauxite to electrolytic aluminum. This integrated process enables optimum exploitation of available local resources and provides environmental benefi ts.

Core and auxiliary processes are controlled by a Simatic PCS 7 process control system engineered and commissioned by Siemens Industrial Automation Ltd., Shanghai (SIAS). The combination of local engineer-ing and industry expertise provided by SIAS and the open and fl exible architecture of the Simatic PCS 7 system proved to be key factors in this milestone project in the Chinese nonferrous metals industry. The key requirements for the distributed control system (DCS) are reliability and availability, ensuring effi ciency and process safety during alumina process-ing, and smooth integration of third-party systems and devices as well as the enterprise resource man-agement system. The solution presented by Siemens and SIAS met all these criteria.

F o c u s C h i n a

S y s t e m h i g h l i g h t : i n t e g r a t i o n

3 One comprehensive control system for planning, primary/secondary processes, and inbound/outbound logistics

3 Seamless integration of all electrical equipment into the automation system

3 Open system enabling easy integration of third-party components and solutions


Project execution in two phases

The refi nery was constructed in two phases. After completion of the fi rst phase in 2006, production capacity for alumina was 1 million tons per year. Currently, LNJB is commissioning the second phase, which will expand the alumina production capacity to 3 million tons per year. For the fi rst phase, SIAS deliv-ered a comprehensive process control package for the refi nery and a 3 x 25 MW power plant for the facility. The contract consisted of all the hardware and soft-ware components for the Simatic PCS 7 system, including the application software development, as well as project management, systems integration, commissioning, training, and other services. The second phase added another alumina refi nery and a dedicated power plant, also controlled by the Simatic PCS 7 system. Moreover, the new sintering plant currently under construction will also use Simatic PCS 7 technology. Overall, the installed solution addresses more than 37,000 I/O points. A separate Simatic PCS 7 system for each plant controls the two refi neries, the two power plants, and the two sintering plants in the refi neries; another system is installed within the raw materials preparation area. The opera-tor systems are networked via an optical Industrial Ethernet ring, while a redundant Profi bus DP network connects to the systems at the process level. For availability reasons, the integrated system architecture uses redundant AS 400H automation systems.

LNJB is striving to further reduce energy consump-tion and costs, for example, through the installation of energy-effi cient motors and implementing variable-frequency converters networked via Profi bus. The energy monitoring and management features of Simatic PCS 7 and the matching services of Siemens provide signifi cant added value. Siemens also sup-plied motors, converters, and instrumentation to the LNJB facility.

Excellent results and ongoing collaborationLNJB is very satisfi ed with the knowledge and exper-tise of Siemens and SIAS, so the project collaboration continues. Currently, SIAS, Siemens, and LNJB are working on implementing Advanced Process Control (APC) strategies in the sintering furnace DCS and energy management throughout the plant to opti-mize process performance and effi ciency. With these projects, LNJB aims to reach the target capacity and quality, to improve asset and performance manage-ment, and to achieve a higher level of automation that will contribute to increased profi tability. p

infocontact


Real-time video information from the process is provided in the central control room

Simatic PCS 7 provides comprehensive access to process data, resulting in higher effi ciency and better performance

For Liu Hongli, deputy director of the maintenance department of LNJB, the central benefi ts of the plant automation with Simatic PCS 7 are signifi cantly increased operational reliability and an improved production cost position

all p

ho

tos:

Go

ng

kon

g

states Dr. Li Jinsong, general manager of SIAS, but it was worth the effort: “The petrochemical industry is a very competitive market, and it was evident that we had to be a player in this industry to demonstrate to systems integrators and solution providers that we are accepted as a DCS supplier with our Simatic PCS 7 system.”

Supported by Siemens in Germany, the SIAS engi-neers co-developed and improved the engineering tools for PCS 7, and they also optimized the Chemi-cals Library and standardized it for use in refi neries. Thanks to the continuous refi nement process for the engineering tools, which was aided by fi eld trials, engineering effi ciency has improved by 30 percent per year almost every year since 2006.

A contribution to excellenceThe performance and quality demonstrated in the PCS 7 engineering tools can be attributed to a large degree to the commitment and successes achieved by the SIAS engineers in the Qingdao project. “This is an important benefi t for Siemens that has resulted from the Qingdao project,” says Li. “Siemens made an investment in this project, and we can proudly say that it has paid off. We successfully completed the Qingdao refi nery project in 2008, and we man-aged to truly impress the customer – for example, with the extremely short commissioning period of just three months. Considering that this is a large system with some 20,000 I/O devices, this was a great achievement indeed. And ever since produc-tion start-up, the plant has been in operation 24/7.”

The Fushun refi nery of CNPC was the next mega-project. The system needed for this plant was even larger – 30,000 I/O devices – and Siemens was able to secure the contract for the DCS and safety instru-mented system (SIS) packages. Just six months later, Siemens was also contracted to supply the Simatic PCS 7 DCS and SIS for the ethylene plant at Fushun and to perform the migration of all plants at Fushun.

Siemens Industrial Automation Ltd., Shanghai (SIAS), is a recognized

solution provider and has become the backbone of Siemens’ success as a

distributed control system (DCS) supplier in the Chinese market. SIAS has

successfully completed a series of fl agship projects in several industries –

for example, in two large Chinese refi neries.

SIAS was founded in 1995 and enjoyed robust growth along with the process industries in China. However, in order

to be truly recognized in the industry, SIAS needed fl agship projects in the market

segments of chemicals and pet-rochemicals, which are

the largest seg-

ments in the Chinese

industry. So in 2006, SIAS launched a develop-

ment plan that defi ned in-creasing market acceptance,

inclusion in vendor listings, and winning megaprojects as its main

targets. At the same time, SIAS estab-lished a dedicated team to identify and

develop market opportunities and to pro-mote Simatic PCS 7 – a process control sys-

tem that at the time was already successfully deployed in many process industries in Europe

and the Americas but was not yet established in China. Due to excellent performance by the team, SIAS managed to secure two large con-tracts in petrochemicals: implementing DCS for Sinopec’s Qingdao refi nery and for China National Petroleum Corporation (CNPC) in Fushun. These two projects marked the breakthrough of SIAS and Simatic PCS 7 in the Chinese process industries.

A diffi cult journey to successTo reach these goals, SIAS had to build up solution expertise as well as engineering and project exper-tise among its staff. It was a long and diffi cult road,

p SIAS, China

Growth through Expertise

F o c u s C h i n a


Foto

lia / e

yew

ave

“The largest growth potential is still in the chemical and petrochemical industry. SIAS will constantly enhance competence in the chemical and petro-chemical industry based on breakthroughs in refi n-ing and ethylene. The pharmaceutical industry will be another growing market in the next wave, as the Chinese government is forcing this sector to increase its level of automation. The demand for clean energy will also speed up growth in the solar business. SIAS has the right solutions and expertise in these mar-kets. We want to expand our collaboration with sys-tems integrators and solution providers to promote joint growth. And, certainly, we want our customers to come back to us whenever they have a new proj-ect. So there is still a lot for us to do, and we are looking forward to the future!” p

On the way to future growth

“China is a fast-growing but highly competitive mar-ket, and we need to keep up with that. Since the economic downturn, cost effi ciency has become an increasingly important topic,” says Li. “Therefore, we expanded our main automation vendor (MAV) business and life cycle services. This addresses pri-marily our project management capabilities. Our employees are our core asset. Through continuous training, we develop the capabilities of our project engineers. And as more and more of our customers consider the operational costs over the lifecycle of a plant, lifecycle services have become an important part of our offering. Today we have a workforce of more than 300, and we are well positioned to face the challenges of the future. Our business success is mirrored in the commitment and spirit of our staff as well, who look forward to shaping the future with us.

infocontact


S p i r i t i n a d v a n c e d s o l u t i o n s

Siemens Industrial Automation Ltd., Shanghai (SIAS), was established in 1995 by Siemens Ltd., China. SIAS provides a broad range of in-depth expertise in industrial automation and is the leading process control solution provider for Siemens in China.

SIAS serves customers in the chemical and petrochemical industry; the glass, cement, and semiconductor industries; the urban infrastructure sector; and the pharmaceutical and food and beverage industries.

SIAS delivers solutions for electrical systems, process automation, and process instrumentation, complete with all related project, engineering, training, and lifecycle services. A dedicated OEM solution department provides tailored automation solutions for machine builders.

» China is a fast-growing but highly

competitive market, and we need

to keep up with that. «Dr. Li Jinsong, General Manager, SIAS


SIA

S

SIA

S


F o c u s C h i n aNCPC is a leading manufacturer of several antibiotic drugs of the cephalosporin family of antibiotics – the illustration shows the antibiotic cefradine – as well as other antibiotic drugs such as penicillin, amoxicillin, and streptomycin sulfate

Shijiazhuang in Hebei province. This greenfi eld pro-duction facility meets the requirements of local authorities to relocate industrial operations out of the city center, but NCPC also seized the opportunity to improve its operations by introducing new tech-nologies. “The plant is built for producing new ceph-alosporin products mainly for the Chinese market but we also target the global market. With this in mind, the plant is equipped with the most modern machines one can buy on the global market and has the highest level of automation,” explains Wei.

A strategic partnershipWith a total investment of 2 billion RMB, the high signifi cance of the new cephalosporin project within NCPC is quite obvious. For such an important proj-ect, NCPC chose trusted partners for the project exe-cution. “With the combination of the most modern automation solutions and expertise in the pharma-ceutical market, we regard Siemens in the forefront of automation suppliers,” Wei continues. Moreover, Siemens has a very good reputation and position in

For nearly 10 years, North China Pharmaceutical Group Corp. (NCPC) has been

relying on Siemens automation solutions and pharmaceutical industry expertise. This

collaboration with Siemens has facilitated the deployment of innovative technologies

within NCPC that contribute to product quality and process performance.

NCPC was founded in June 1953 as one of the key projects of the fi rst Chinese Five-Year Plan. The company’s fi rst production unit

commenced operation in 1958. Ever since, NCPC has been growing through innovation and technology. Today, NCPC is among the most successful Chinese companies and not only serves the domestic market but is also targeting global pharmaceutical demand. However, in order to remain an industry leader, NCPC has to continue improving performance and driving innovation, says Wei Qingjie, board chairman and general manager of the newly established NCPC Hebei Huamin Pharma Co. Ltd. “As we are facing growing competition in the Chinese pharmaceutical market, we must have the highest standards of qual-ity in our production plant in order to keep our lead-ing position. And to fulfi ll this we need a partner that is able to cooperate with us on this target.”

The latest move in company strategy was made with the recently initiated new cephalosporin project in the New Technological Development Zone of

p North China Pharmaceutical Group Corp., China

Trusted Partner

Foto

lia / C

hristin

a Po

lley

Looking forward to continuing the partnership (from left to right): Feng Ke Ting, Siemens account manager for NCPC; Wei Qingjie, board chairman and general manager of Huamin Pharma Co. Ltd., and Wolfgang Scheiding, head of Global Vertical Market Management Pharmaceutical Industry, Siemens


T h e n e w c e p h a l o s p o r i n p r o j e c t

Siemens provided a comprehensive set of systems and solutions to NCPC:

3 Simatic PCS 7 control system for

3 Non-aseptic production of APIs (active pharmaceutical ingredients)

3 Simatic WinCC SCADA system for

3 Aseptic powder fi lling

3 Manufacturing of oral solid dosages

3 HVAC for the R&D building

3 Energy management system

The entire project was executed by SIAS

(Siemens Industrial Automation Ltd., Shanghai).

The engineering services comprised the overall

project implementation strategy, functional

design specifi cations, hardware and software

architecture, network construction,

documentation of all procedures, engineering

design, confi guration and commissioning, and

integration and commissioning of third-party

systems as well as operation and maintenance

support services.

the Chinese market and a strong local presence that offers good on-site support. The most important aspect, however, was trust, says Wei: “We have a long history with Siemens and have already exe-cuted other successful projects with the Simatic PCS 7 DCS.” The collaboration between NCPC and Siemens has been ongoing for more than 10 years and the partnership has been very benefi cial for both parties, confi rms Feng Ke Ting, Siemens key account manager for NCPC: “We have the opportu-nity to work together very closely and exchange ideas at a very early stage of the projects. This helps open up new opportunities and synergies in terms of innovation and development.” This view is shared by NCPC: “We hope that by making our partnership stronger and stronger we will benefi t much more in

the future from Siemens as a leader in technolo-gies,” says Wei.

The new cephalosporin project was started with the foundation of NCPC Hebei Huamin Pharma Co. Ltd. in October 2009. Siemens provided a comprehensive process control solution based on Simatic PCS 7 for the entire production process, and the project exe-cution and systems engineering was performed by Siemens Industrial Automation Ltd., Shanghai (SIAS) (see top of page). Now, just one year later, the proj-ect is completed and ready for validation. This chal-lenging time schedule was possible only because of very close cooperation between the Siemens project engineers from SIAS and NCPC. Wei is absolutely sat-isfi ed with the project run. “This project proved that we made the right decision in choosing Siemens as the main supplier for this project,” he says.

A bright prospect for future projectsWhile the new cephalosporin project is complete, the relocation of existing NCPC plants to the New Zone is still going on. Just opposite the new cepha-losporin plant, NCPC is currently building a new for-mulation plant with fi ve production lines for inject-ables, oral solid dosage forms, and capsules. The targets for completing this project are again very ambitious – one year. While NCPC is still evaluating various automation system providers, Siemens has a good chance of winning this project as well and con-tinuing the fruitful partnership of the two compa-nies. p

infocontact


Siem

ens

AG

Siemens AG


K u r z n o t i e r tI n B r i e f A s i a

PetroChina, China

The Next Petrochemicals Megaproject

With the new ethylene cracker on stream and several other plants currently completing commissioning, the Fushun Petrochemical complex is on track to become another major petrochemical production hub in China. The complex will be the largest refi nery chemical base in China’s northeastern region and integrates a refi nery plant with a production capacity of 10 million tons per year and an ethylene and polyolefi n complex with a capacity of 1 million tons per year, making it a landmark project for integrated petrochemical processing in China. For both the refi nery and the ethylene and polyolefi n complex in Fushun, Siemens was chosen as the main automation vendor against tough competition. Siemens was able to impress the complex owner Fushun Petro-chemical Co., a subsidiary of the China National Petroleum Corpo-ration (CNPC), with a comprehensive systems and services pack-age. For both projects, Siemens provided a comprehensive combined distributed control system (DCS) and safety instru-mented system (SIS) based on Simatic PCS 7, complete with the associated services. p

www.siemens.com/process-safety

Lanxess, Singapore

Integration Package

The new Lanxess butyl rubber plant in Singapore will be equipped with an integrated electrical distribution and automation solution based on the Simatic PCS 7 process control system. Siemens has been con-tracted to deliver and commission the automation system and the electrical distribution system for the new butyl rubber production facility on Jurong Island. The scope of delivery comprises a Simatic PCS 7 system with intelligent protection and control devices networked via Profi bus. The process control sys-tem will provide plantwide power monitoring, asset management, and an emergency shutdown sys-tem offering protection up to SIL 3. The control system will also enable easy integration of package units such as compressor trains, which are also supplied by Siemens.

Lanxess is the world’s largest manu-facturer of specialty synthetic rubber. The company is a leading specialty chemicals company and is represented at 42 production sites worldwide. The new Lanxess pro-duction facility on Jurong Island is the most advanced of its kind in Asia. p

www.siemens.com/pcs7

Heineken Asia Pacifi c, China

Full Range

Siemens was selected to provide a complete range of process instruments for the new brewery of Guangzhou Heineken Asia Pacifi c Breweries. Siemens will supply instrumentation for more than 400 measuring points, including food & beverage-certifi ed and standard Sitrans F fl owmeters, Sitrans P pressure transmitters, Sitrans L level switches, Sipart positioners, and Sitrans T temperature transmitters.

The brewery is being built at the Yun Pu Industrial Park, Huangpu District, and covers about 205 acres. The plant is committed to the environmental protection and quality principles of the Heineken Group of breweries and will utilize the most advanced equipment. The targeted annual output of the brewery will be up to 20 million liters. The main products of the new brewery will be the popular Heineken brands Hunter, Tiger, and Li Jia. p

www.siemens.com/processinstrumentation

Foto

lia / t

ou

rne

e

Petr

oC

hin

a

Lan

xess

The Set VGU with redundant pump isolates the fl are header pressure and analyzer


T e c h n o l o g y P r o c e s s A n a l y t i c s

Environmental legislation places increasingly strict restrictions on emissions to air – and process analyzers must meet these require-

ments and emission limits just like any other emis-sion source, no matter how small the total amount of gas emissions. This fact often necessitates condi-tioning of sample gas prior to disposal. Often, gas fl ares are used for this purpose. However, the fl are header pressure is typically not constant and can exceed 1 bar of back pressure, depending on the load. This change in pressure can impact the accu-racy of the analyzer system.

Low maintenance needs, simple and precise operationSiemens has developed a special device set for vent gas units that isolates the analyzer from the fl are gas pressure. The Set VGU consists of a pressure trans-mitter, a compact controller, a frequency converter, and a gas pump in a compact panel for ease of operation and installation. The pressure transmitter is connected directly to the vent header, providing a 4 – 20 mA output signal for the controller, which is in turn connected to the Micromaster 420 frequency converter. Based on the mean pressure value setting, the Micromaster 420 changes the electrical fre-quency that is used to address the gas pump. This approach ensures constant pressure in the vent header regardless of the discharge volume and back pressure.

The sole mechanical component of the system is the inert high-effi ciency diaphragm gas pump. The pump is designed as a redundant system to enable servicing during operation and to ensure system availability when one pump fails.

Process gas analyses not only deliver a measurement result but also yield a certain

fl ow of vent gas. The Set VGU vent gas unit enables controlled feeding of the exhaust

gas into the vent gas fl are at the analyzer shelter so that the gas can be disposed of

with minimum emissions.

p Vent Gas Unit

Strictly Controlled and Eco-Friendly

Designed for easy installation and cost-effective retrofi ts

The Set VGU is designed for operation as a stand-alone unit and is available in ATEX category 3G. The compact and standardized design makes for easy implementation into an existing environment. The vent gas unit therefore enables not only controlled and eco-friendly disposal of analytic gas samples but supports a cost-effective retrofi t – offering benefi ts for both the environment and the plant opera-tor. p

From vent gas header

Sitrans P

Compact controller

To flare

Micro-master

420

infocontact


Siem

ens

AG


I n d u s t r y P l a s t i c s

Pellets, powders, and often also pigments and fi bers are the raw materials for high-quality plastics. In order to achieve the desired prop-

erties in the fi nal product, the component com-pound must be absolutely uniform. Compounding also generates heat, which must be dissipated reli-ably in order to ensure operational as well as equip-ment and environmental safety.

Buss’s innovative machines set the global standard, especially for demanding heat- and shear-sensitive applications. The kneaders from Buss are perfectly suited even for sophisticated compounding tasks

The Swiss company Buss shows that increasing both fl exibility and safety

is possible in kneader systems – for example, with the MX kneader series

designed for producing demanding cable compounds.

p Buss AG, Switzerland

Clever Compound

and feature rapid product changes, high reliability, long service life, and maximum productivity.

Innovation for greater safety and fl exibilityThe company is continuously refi ning its compound-ing technology and transforms all its fi ndings into customer benefi ts. The MX series was developed especially for the production of high-tech plastic compounds for cable jackets. The initial product, raw plastic pellets, is melted and mixed with func-tional additives. Stephan Jurt, manager of process control systems at Buss AG, describes the high demands on this process: “Additives often account

Excellent process visibility even from a distance: the Simatic Multi Panel MP 377 Key with a WinCC fl exible interface

all p

ho

tos:

Bu

ss A

G


display is programmed with the Simatic WinCC fl exible HMI software. Buss uses the Simatic ET 200S distributed I/O system with fail-safe I/O mod-ules to ensure optimum safety while reducing wiring. The simpler system architecture has signifi -cant benefi ts for both Buss and its customers. All machines are assembled at the Pratteln factory and tested prior to shipment. The Simatic ET 200S modules greatly simplify both wiring during on-site assembly and commissioning. The machine opera-tors additionally benefi t from lower costs for spare parts stocking and low service expenses in ongoing operation.

“With the Simatic S7 F-series products, we meet the ISO 13849 safety standard. Of course, we also have to certify this safety,” Jurt explains. Every machine is therefore evaluated and certifi ed with the Siemens Safety Evolution Tool, which is available free of charge via the Siemens Web site. This solution is ideal for Jurt: “Both machine and controller are easy to use. As our extruders are used worldwide, we need a controller that is globally accepted, and we expect 24/7 service if needed. Siemens meets all these demands.” p

for only a small part of the compound – and despite that, they still must be optimally distributed in the compound.” Another challenge is the heat produced during compounding, which can lead to overheat-ing of these often very heat-sensitive products. Thanks to its unique operating principle, the spe-cially developed kneader ensures optimum and uniform mixing and strict temperature control over the compounding process.

“For Buss, quality is key in every respect,” stresses Jurt. “The kneader was developed for high-quality plastics and is also ideally suited for smaller vol-umes. But such high-quality machines also need excellent control systems. We have selected Siemens products for this.” Automation is particu-larly important for process safety: The compounder is cleaned carefully every time the product or color is changed. The kneaders can be opened and can be cleaned easily. This provides a considerable time advantage, especially with frequent product changes. However, discharging the extruder can potentially pose a safety risk. To ensure operational safety, the MX series is equipped with a fault-tolerant Simatic S7-315 F-2DP controller that handles both safety-critical and nonsafety control tasks.

Lower costs and certifi ed safetyCombining safety and standard applications on one control system reduces costs for hardware and engineering. The Simatic Multi Panel MP 377 Key is used as an interface for the machine operator; the

» Thanks to the ET 200S

distributed I/O system we

achieve optimum safety

while reducing wiring. «Stephan Jurt, Manager, Process Control Systems, Buss AG

infocontact


process news | 2-2011

R u b r i k U n t e r r u b r i kI n d u s t r y F o o d a n d B e v e r a g e

Palm Breweries is a brewer of genuine Belgian beers and the only brewer in the world to brew using all four fermentation methods (top, bot-

tom, spontaneous, mixed). An independent family-run brewing group, the company owns breweries in Steenhuffel and Roeselare and also operates a joint venture with brewer Frank Boon in Lembeek, Bel-gium.

A unique taste for ambitionThe brewery group has made determined efforts over the years to maintain the unique and regional beer styles in their original form. Their beers, such as Rodenbach, Palm, Brugge Tripel, and the Geuze Beers by Boon, contribute to the beer culture that makes Belgium so unique. At the same time, Palm Breweries is a growth-oriented company and doubles its volume every 10 years.

Realizing this ambition and combining it with the company’s high quality standards motivated Palm Breweries to become an example of wall-to-wall traceability. For this purpose, Palm Breweries put together a dedicated manufacturing execution sys-tem (MES) project team consisting of production management, logistics management, lab manage-ment, and IT personnel. The team made a business case by carefully mapping and calculating the expected costs and advantages of such a new sys-tem so as to justify the investment to the board of directors.

This business case was the basis for detailed user requirement specifi cations drawn up according to the ISA-95 standard, the common “language” of MES vendors and systems integrators. After an extensive evaluation of available systems and suppliers, Palm

With an MES based on Simatic IT, Palm

Breweries has achieved and even

exceeded its strategic goals of

improving traceability and integrating

quality and process improvements in

two breweries in Belgium.

p Palm Breweries, Belgium

Consistently Unique

Palm

Bre

wer

ies

process news | 2-2011

infocontact


ily create their own reports. The reporting on KPIs enables benchmarking and root cause identifi cation, and also enables hourly performance evaluation to correct any deviations from the desired process parameters. Moreover, the historian functionality of the system will allow Palm Breweries to improve the process and quality by interpreting, correlating, con-textualizing, and trending historical data. This was already demonstrated when the company was able to achieve a more consistent quality of two beer tastes through a modifi cation in the recipe.

Concrete business benefi tsWith the Simatic IT MES in place, Palm Breweries has seen immediate benefi ts, especially in terms of pro-duction and quality-related costs. Linking process and quality data makes it possible to relate losses to a specifi c lot, process step, or period and to make comparisons in order to reveal potential for material and energy savings. Interfacing the planning module in the MES with the purchasing module in the enter-prise resource planning (ERP) system facilitates plan-ning and puts the brewer in a better position for sourcing packaging material. Together with produc-tion monitoring, Simatic IT Unilab has led to improved quality consistency and an increase in the in-house quality index at Palm. In addition to cost savings, the new system also contributes to job satis-faction for Palm staff, says Alex De Smet, production director at Palm Breweries: “We have achieved our major targets and even exceeded some. Equally important, having a reliable system in place contrib-utes to a professional environment that empowers the workforce to be more effi cient and inspires self-confi dence and additional potential for improve-ment.” p

Breweries awarded the contract to the systems inte-grator Actemium, which had proposed a solution based on the Simatic IT MES.

Focus on visibility and qualityActemium implemented an MES using Simatic IT Pro-duction Suite and the Simatic IT Unilab laboratory information management system (LIMS). Simatic IT Production Suite receives production orders from the production planning application based on sales fore-casts. These production orders are graphically visual-ized to facilitate detailed production planning and the issuing of orders. Operators receive their orders on-screen at the production line, together with all relevant details, such as which quality checks to per-form, and the bill of materials. Data for tracking and tracing purposes are registered per lot. At the end of the bottling line, fi nished products are palletized and labeled with a pallet label generated by Simatic IT. Related information is captured and fed back to the logistics system to ensure traceability toward the customers.

When a production order is created, Simatic IT Unilab determines a sampling and testing routine for each production step, including the end products. Lab personnel as well as operators receive clear work lists and know which samples to take and which analyses to perform. The capturing of test results is automated. This saves a lot of time and helps improve data quality by avoiding the errors that can be introduced through manual data entry. All analy-sis results are checked against parameters and stored in Simatic IT Unilab. The release or hold of raw mate-rials or products is based on these test results.

During each production step, Simatic IT Report Man-ager creates reports for key performance indicator (KPI) monitoring and analysis. A number of the reports used at Palm Breweries were designed by Actemium, but the authorized users at Palm can eas-

K e y b e n e f i t s : S i m a t i c I T a t P a l m B r e w e r i e s

By implementing an MES based on Simatic IT, Palm Breweries set up an integrated quality control and traceability system that contributes to the company’s image and brand value. In addition to higher customer satisfaction, improved regulatory compliance, reduced energy consumption, and increased job satisfaction for staff, Palm Breweries achieves improved quality at signifi cantly lower costs:

3 25 % reduction in off-spec product cost

3 2.5 % reduction in cost of packaging materials

3 2 % reduction in auxiliary material consumption

3 1 % reduction in raw material consumption


p Aker MH, Norway

Virtual DrillingAker MH uses high-end automation technology

for operator training. This approach allows

comprehensive 3-D simulation of real conditions

and considerably reduces environmental impact

and energy consumption.

I n d u s t r y O i l a n d G a s


The Aker MH company – a subsidiary of Aker Solutions, headquartered in Kristiansand, Norway – supplies the offshore oil and gas

industry with complete technologies and systems for deep-sea drilling. Aker Solutions’ key corporate objective is the development of high-performance solutions that meet maximum standards for safety, effi ciency, and usability.

Realistic conditionsAn important fi eld of business for Aker is training offshore rig operating personnel. In its own training center, Aker uses the same automation hardware and software and the same operating environment as on the offshore rigs. In this way, all procedures can be practiced in a completely realistic simulation, in real time and in 3-D, without having to move the large machines and systems. This approach reduces environmental impact, emissions, and power con-sumption. Additionally, training effort is minimized without compromising training quality. Operators can be trained to optimally respond to faults, says Bjarne Larsen, head of development in the research and development department at Aker Solutions: “Such realistic training would be impossible without the Siemens automation products that are set up identically on the rigs and in the training centers.”

Automation concept for real timeHydraulic systems are used on offshore drilling rigs for handling heavy loads such as the drill pipe, and automation has to be tailored to the specifi c require-ments, with hardware offering a high computing performance and a real-time operating system (RTOS). Aker Solutions combined standard automa-tion products with its own Robotic Motion Control (RMC) software. The software is based on an RTOS platform and meets the industry-specifi c require-ments for drilling applications. RMC requires an extremely high computing capacity and is therefore executed on industrial computers. Aker Solutions uses the PC-based Simatic WinAC (Windows Automa-tion Center) RTX controller. WinAC RTX brings stan-dard automation technology into the openness and fl exibility of the PC environment and uses an RTOS, just like the RMC software from Aker. All applications for HMI tasks and technical functions can be com-bined easily in a total automation solution. Another key component is the WinAC Open Development Kit (ODK) option, which connects WinAC and RMC and therefore enables data exchange. The ODK offers access to all hardware and software components on the Aker computers and allows vertical and horizon-tal integration with other applications. “By replacing our old controllers with the WinAC RTX software controllers, we reduced the number of hardware components and were able to accommodate every-thing in one box,” Larsen explains. “Thanks to the compatibility between WinAC and our own RMC soft-ware, the integration between the two was no lon-ger a question of programming but of confi gura-

tion.” Like the modular controllers, WinAC can also be programmed with Simatic Step 7. Aker uses Step 7 Professional because of the high-level lan-guages that it contains.

Installable on any powerful computerWith the introduction of WinAC, the manufacturer decided to change over its system programming to Structured Control Language (SCL). SCL is similar to Pascal and enables the programming of simple or complex applications. It is particularly suitable for complex algorithms and mathematical functions and is transparent as well as adaptable. The graphical programming language S7 Graph (SFC) is also used.

S7 Graph improves the legibility and traceability of the programs. Mechanics, hydraulic technicians, and programmers can all understand the program equally well and can therefore work together on an automation solution. Aker Solutions’ automation solutions for drilling applications based on Siemens products can be installed on any computer with the necessary processing capacity. “Thanks to the use of Step 7 and WinAC, our automation solution has become more fl exible and has more added value,” Larsen explains. “It is now more open, allowing for new technologies and user requests, and can easily be upgraded with new computer hardware.” These benefi ts are available on the offshore rig and in the simulation. p

With Simatic Step 7 and WinAC RTX, Aker is even more fl exible in the implementation of automation solutions

» Our automation solution has

become more fl exible and has

more added value. «Bjarne Larsen, Head of Development,Research and Development Department, Aker Solutions

infocontact


all p

hot

os:

Sie

men

s A

G


I n B r i e f

78 GHz radar level transmitter

Solid Specialist

With the Sitrans LR560, Siemens has launched the fi rst radar level transmitter operating at 78 GHz frequency. The device is particularly suited for measuring solids levels and has a measurement range of up to 100 m.

The 78 GHz non-contacting 2-wire FMCW (frequency-modulated continuous wave) emits a short wavelength to provide excep-tional signal refl ection even from solids with a steep angle of repose. The narrow 4 ° beam avoids interferences from silo wall obstructions and other installations, allow-ing the device to be installed practically anywhere on the top of the silo.

The unique lens antenna is highly resistant to material buildup, and an integrated purge connection is included for cleaning exception-ally sticky solid mate-rial. p

www.siemens.com/sitranslr560

I/O Extender for MicroSAM

Communication Expert

The new I/O Extender provides an improved fi eld solution for MicroSAM. The power-ful input and output module can be installed directly in explosion-hazardous areas with a suitable housing. The device is certifi ed for use in ATEX Zones 1 & 2 and Class 1 Div. 2. The standard unit offers the following set of inputs and outputs: 4 digital inputs, 4 digital outputs, 2 analog inputs, 4 analog outputs. The I/O-Extender offers an intrinsically safe design and tolerates a broad temperature range so that the device can also be installed close to the MicroSAM in tough ambient conditions. Combining several I/O Extender devices enables fl exible adaptation to different applications and an infi nite extension of the number of input and output signals. The device is easy to install and de-install and is maintenance-free in operation. The MicroSAM I/O-Extender solution helps save footprint in analyzer shelters and is perfectly suited for remote installation with limited infrastructure. p

www.siemens.com/processanalytics

First certifi ed biomethane measuring system with Siemens process gas chromatograph

Analyzer Solution for Biogas Feed-inMarquis GmbH from Witten, Germany, has partnered with Siemens in the certifi cation of a complete solution package for custody transfer measurement of biomethane at the German Physikalisch-Technische Bundesanstalt (PTB) institute. The main component of the solution is the special MicroSAM CV process gas chromato-graph that is integrated into the package unit. MicroSAM CV measures the concentration of all typical components of the processed biogas. Based on the analyses, quality parameters such as calorifi c value, density, or Wobbe index can be calculated. With their analytics expertise, Marquis GmbH and Siemens help address the issue of fossil fuels exhaustion, as biomethane generation and biomethane process analytics play an important role in this context. p

www.siemens.com/sitranscv

ns antenna tant toup, and purgeincluded xception-d mate-

.com/

e elters

D i a l o g u e


process news 2-2011PublisherSiemens Aktiengesellschaft,Gleiwitzer Str. 555, 90475 Nuremberg, Germanywww.siemens.com/automation

Drive Technologies DivisionCEO Ralf-Michael Franke

Industry Automation DivisionCEO Anton S. Huber

Editorial Responsibility in Accordance with the German Press LawArno Hoier

Responsible for Technical ContentCornelia Dürrfeld

ConceptChristian Leifels

EditorCornelia Dürrfeld, Siemens AG, I IA AS S MP 7Siemensallee 84, 76187 Karlsruhe, GermanyTel.: +49 (0) 7 21 5 95-25 91Fax: +49 (0) 7 21 5 95-63 [email protected]

Editorial CommitteeSigrun Ebert-Heffels, Ute Forstner, Petra Geiss, Michael Gilluck, Walter Huber, Roland Wieser

Publishing HousePublicis Publishing Postfach 32 40, 91050 Erlangen, GermanyTel.: +49 (0) 91 31 91 92-5 01Fax: +49 (0) 91 31 91 92-5 [email protected]

Editor in chief: Kerstin PuruckerLayout: Stefanie Eger, Jürgen StreitenbergerCopy editing: Juliana LankesDTP: Mario Willms

Printing: Wünsch, Neumarkt, Germany

process news is published quarterly

Cover photo: Fotolia / Sunnydays

Circulation: 30,000

Job number: 002800 31287

© 2011 by Siemens Aktiengesellschaft Munich and Berlin

All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper. ISSN 1430-2284 (Print)

The following products are registered trademarks of Siemens AG:ET 200, MICROMASTER, S7-400, S7-300, SCALANCE, SENTRON, SIMATIC, SIMATIC Batch, SIMATIC IT, SIMATIC PCS 7, SIMATIC RF, SIMOCODE, SIMOVERT, SINAMICS, SIPART, SIRIUS, SITRANS, SIVACON, STEP, TELEPERM, TIA, WinAC, WinCC

If trademarks, trade names, technical solutions, or similar are not listed above, this does not imply that they are not registered.

The information provided in this magazine contains merely general descriptions or characteristics of performance, which in the case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall exist only if expressly agreed in the terms of contract.

IWI: TPOGOrder number: E20001-M6211-B100-X-7600Printed in Germany

onlinewww.siemens.com/processnews

Here you can download the current issue and past issues of process news as PDF files, or search directly for articles about specific topics, technologies, and systems in the Reference Center.

onlineNew process news online edition

Survey Results

In the last issue of process news, we asked you to take part in a short survey to help us improve the way we provide you with process automation information online – and quite a few readers took the time to answer the questions. So first of all, we would like to thank you for your participation and feedback.

What we have learned from your answers is that a vast majority (more than 80 percent of all answers received) would like to see an online version of process news, and 37 percent of all participants stated that this would increase their interest in the printed version. Most (78 percent) of our readers would access the online edition from their office PC.

So one conclusion for us is that we will expand and build the process news Web site to provide you more frequently updated information on focus industries and technologies. We are looking forward to this new online edition and hope that you are, too.

In the meantime, the existing Web site will continue to contained in provide you with all the information the print magazine and to offer a magazine archive and article database.

Visit process news on the Internet:www.siemens.com/processnews

infoDo you want to know more about the systems and solutions for the process industry from Siemens Automation and Drives? Simply visit our information portal on the Internet at:

www.siemens.com/processautomation

Do you want to change your address? Subscribe to process news? Comment on articles in process news or request more information? Just send us an e-mail:

[email protected]

Answers for industry.

Perfect control of all quality aspects in the pharmaceutical and life science industries.

Siemens expertise and solutions for research and development, manufacturing, utilities and business processes, as well as a commitment to the environment help the industry to minimize risk, increase efficiency and improve patient safety. www.siemens.com/pharma

What are the ingredients for your business success?

rp112_s01_titel en.indd

Documents